Orbital welding device with improved security and reduced failure probability

ABSTRACT

An orbital welding device ( 1 ) having a welding head ( 2 ), the welding head having a tubular mount ( 3 ) and a welding electrode holder ( 4 ) rotatably supported with respect to the tubular mount ( 3 ), the orbital welding device ( 1 ) having an electric motor ( 6 ) activated by a motor controller ( 5 ) of the orbital welding device ( 1 ), which is configured to drive the welding electrode holder ( 4 ) and thus to rotate the same with respect to the tubular mount ( 3 ), wherein the orbital welding device ( 1 ) has an electric torque measuring device ( 7 ), which is configured to measure a torque applied by the motor ( 6 ) to the welding electrode holder ( 4 ), wherein the torque measuring device ( 7 ) is connected to the motor controller ( 5 ), and wherein the motor controller ( 5 ) is configured to stop the motor ( 6 ) automatically if the torque exceeds a predetermined first torque.

The invention relates to an orbital welding device. Such a device isshown, for example, in DE 20 2014 100 284 U1.

A welding device is described in U.S. Pat. No. 6,380,505 B1, and it ismentioned in passing that, instead of an extension shaft, an adjustableslipping clutch can be used in order to increase user safety and toprevent damage.

Nevertheless, the inventors found it worthy of improvement to increasethe safety and reduce the probability of failure. The object of thepresent invention is to carry out this improvement. The object isachieved by the independent claims. Advantageous developments aredefined in the sub-claims.

In particular, the object is achieved by an orbital welding devicehaving a welding head, the welding head having a tubular mount and awelding electrode holder rotatably supported with respect to the tubularmount, the orbital welding device having an electric motor activated bya motor controller of the orbital welding device, which is configured todrive the welding electrode holder and thus to rotate the same withrespect to the tubular mount, wherein the orbital welding device has anelectric torque measuring device, which is configured to measure atorque applied by the motor to the welding electrode holder, preferablyalways when the motor is activated, i.e. is fed with a drive current,wherein the torque measuring device is connected to the motorcontroller, and wherein the motor controller is configured to stop themotor automatically if the torque exceeds a predetermined first torque.

The object is also in particular achieved by methods for operating anorbital welding device, including the steps:

-   -   rotating a welding electrode holder of the orbital welding        device with respect to a tubular mount of the orbital welding        device by activating an electric motor by means of a motor        controller of the orbital welding device,    -   measuring a torque applied by the motor to the welding electrode        holder by means of an electric torque measuring device,        preferably always when the motor is activated, i.e. is fed with        a drive current,    -   automatically stopping the motor by means of the motor        controller if the torque exceeds a predetermined first torque.

In this way, the safety is increased further and the probability of adefect of the device on account of jamming of the drive mechanism byforeign bodies is reduced.

As opposed to the implementation with a slipping clutch, according tothe invention the motor is stopped. The slipping clutch limits thetorque at most and the motor then always still applies the limitedtorque to the drive mechanism.

The first predetermined torque is preferably stored in the orbitalwelding device. It is higher than the torque which is needed for aproper function of the orbital welding head and represents jamming ofthe welding electrode holder or a drive mechanism between motor andwelding electrode holder.

A motor controller is preferably understood to mean one or more electricdevices which is or are configured to influence an operating state (e.g.rotational speed, torque) of the motor directly or indirectly.

In a further exemplary embodiment of the present invention, the torquemeasuring device has a current measuring device, which is configured tomeasure an electric motor current for driving the motor as a valuerepresenting the torque. In a further method according to the invention,the electric torque measuring device measures the electric motor currentfor driving the motor as a value representing the torque, by means of acurrent measuring device.

In this way, by means of a current sensor, a simple measurement of asignal approximately proportional to the torque is made possible. Thecurrent measuring device is preferably a resistance in the current feedline to the motor, preferably of low resistance.

In a further exemplary embodiment of the present invention, the motorcontroller is configured to start the motor automatically in theopposite direction for a specific time or for a specific number ofrevolutions, directly after the motor has been stopped on account ofexceeding the first predetermined torque. In a further method accordingto the invention, the motor is automatically started in the oppositedirection for a specific time or for a specific number of revolutions bythe motor controller, directly after the motor has been stopped onaccount of exceeding the first predetermined torque.

In this way, the safety is increased still further. Should anindividual, for example, pinch a finger in the drive mechanism, it willpossibly be freed again by the reverse travel.

In a further exemplary embodiment of the present invention, the motorcontroller is configured to stop the motor automatically again if thetorque again exceeds the predetermined torque after the motor has beenstarted in the opposite direction for a specific time or for a specificnumber of revolutions, directly after the motor has been stopped onaccount of exceeding the first predetermined torque. In a further methodaccording to the invention, the motor is stopped again by the motorcontroller if the torque again exceeds the predetermined torque afterthe motor has been started in the opposite direction for a specific timeor for a specific number of revolutions, directly after the motor hasbeen stopped on account of exceeding the first predetermined torque.

In this way, the safety and the probability of a defect of the device onaccount of jamming of the drive mechanism by foreign bodies is stillfurther reduced. Should the renewed jamming occur during the reversetravel (=torque exceeds the first predetermined first torque), the motoris again stopped.

In a further exemplary embodiment of the present invention, the orbitalwelding device is configured to output a visual and/or acoustic and/orhaptic signal automatically or to transmit an electronic signal forvisual and/or acoustic and/or haptic display on another device or tostore the same on a storage unit if the torque continuously exceeds asecond predetermined torque over a predetermined time period, whereinthe second predetermined torque is lower than the first predeterminedtorque. In a further method according to the invention, the orbitalwelding device automatically outputs a visual and/or acoustic and/orhaptic signal or it automatically transmits or stores an electronicsignal for the visual and/or acoustic and/or haptic display on anotherdevice if the torque continuously exceeds a second predetermined torqueover a predetermined time period, wherein the second predeterminedtorque is lower than the first predetermined torque.

In this way, detection of wear is made possible. Should the rotarymechanism gradually become more and more sluggish, for example as aresult of soiling or the drying-out of lubricant, this can beestablished hereby. Either the user is given a visual and/or acousticand/or haptic signal directly or a signal is transmitted, for example,to a central monitoring facility (e.g. main office of a constructionfirm), in order there to output a visual and/or acoustic and/or hapticsignal, or this signal is stored on a storage unit, for example astorage chip of the orbital welding device, in order then, for example,to be read by a service engineer, who then receives the informationabout the occurrence of wear that has occurred, displayed by means ofthe visual and/or acoustic and/or haptic signal.

In a further exemplary embodiment of the present invention, the motorcontroller and the torque measuring device are arranged in a weldingcurrent source of the orbital welding device, while the motor isarranged in the welding head. In this way, the welding head can maintaineasy-to-handle dimensions.

The invention is now to be illustrated further by way of example byusing a drawing.

FIG. 1 shows an orbital welding device 1 having a welding head 2, thewelding head having a tubular mount 3 and a welding electrode holder 4rotatably supported with respect to the tubular mount 3. The orbitalwelding device 1 has an electric motor 6 activated by a motor controller5 of the orbital welding device 1. The motor 6 is configured to drivethe welding electrode holder 4 and thus to rotate the same with respectto the tubular mount 3. The orbital welding device 1 has an electrictorque measuring device 7, which is configured to measure a torqueapplied by the motor 6 to the welding electrode holder 4. The torquemeasuring device 7 is connected to the motor controller 5. The motorcontroller 5 is configured to stop the motor 6 automatically if thetorque exceeds a predetermined first torque.

The torque measuring device 7 has a current measuring device 7.1, whichis configured to measure an electric motor current for driving the motor6 as a value representing the torque.

The motor controller 5 and the torque measuring device 7 are arranged ina welding current source 8, while the motor 6 is arranged in theeasy-to-handle welding head 2.

LIST OF DESIGNATIONS

-   1 Orbital welding device-   2 Welding head-   3 Tubular mount-   4 Welding electrode holder-   5 Motor controller-   6 Motor-   7 Torque measuring device-   7.1 Current measuring device-   8 Welding current source

1-7. (canceled)
 8. An orbital welding device, comprising: a weld headhaving a tubular mount and a welding electrode holder mounted rotatablywith respect to the tubular mount; a motor controller; an electricmotor, which is activated by the motor controller and is configured todrive the welding electrode holder to turn the welding electrode holderwith respect to the tubular mount; and an electrical torque measuringdevice configured to measure a torque applied to the welding electrodeholder by the electric motor, wherein the electrical torque measuringdevice is connected to the motor controller, and the motor controller isconfigured to, in response to the measured torque exceeding apredetermined first torque for at least a predetermined threshold timeperiod, do one or more of: output at least one of a visual signal, anacoustic signal, or a haptic signal; send an electrical signal for atleast one of visual output, acoustic output, or haptic output on anotherdevice; or store an indication on a storage unit.
 9. The orbital weldingdevice of claim 8, and the motor controller is configured to stop theelectric motor automatically if the torque exceeds a predeterminedsecond torque higher than the predetermined first torque.
 10. Theorbital welding device of claim 9, wherein the motor controller isconfigured to start the electric motor automatically in the oppositedirection for a predetermined time or for a predetermined number ofrevolutions directly after the electric motor has been stopped becauseof the predetermined second torque being exceeded.
 11. The orbitalwelding device of claim 10, wherein the motor controller is configuredto stop the electric motor again automatically if the torque exceedsagain the predetermined second torque after the electric motor has beenstarted in the opposite direction for the predetermined time or for thepredetermined number of revolutions directly after the electric motorhas been stopped because of the predetermined second torque beingexceeded.
 12. The orbital welding device of claim 8, wherein thepredetermined first torque is representative of excess wear on theorbital welding device.
 13. The orbital welding device of claim 12,wherein the predetermined first torque is less than a torque at whichthe welding electrode holder, or a drive mechanism between the electricmotor and the welding electrode holder, is jammed.
 14. The orbitalwelding device of claim 8, wherein the electrical torque measuringdevice has a current measuring device, which is configured to measure anelectrical motor current for driving the electric motor as a valuerepresenting the torque.
 15. The orbital welding device of claim 8,wherein the motor controller and the electrical torque measuring deviceare arranged in a welding power source of the orbital welding device,while the electric motor is arranged in the weld head.